Lean 911

Mark DeLuzio
  • 4,2 (15)
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The Lean 911 Podcast is where you'll have a voice directly from the gemba. Host, Mark DeLuzio, President and CEO of Lean Horizons Consulting and the principal architect of the Danaher Business System, relies on his three decades of lean successes as well as his failures to answer your most challenging questions regarding your lean transformation.

  1. -2 ДН.

    The Illusion of Business Logic: Brilliant at Home, Illogical at Work

    In this episode, you'll be able to take away why many "logical" workplace measures and incentives can drive behavior that conflicts with Lean principles, and why comparing work decisions to everyday home-life decisions can make Lean concepts easier to understand and teach. You will hear about various examples, including grocery shopping and volume discounts, which highlight purchase price variance and excess inventory. You will explore the concepts of push versus pull using the supermarket and kanban approach. You'll gain insights into utilization and overall equipment effectiveness (OEE) and understand how "banking" uptime can lead to overproduction and unmet demand. Additionally, you will investigate changeover strategies using a multi-part thermoforming case, illustrated through a barbecue analogy comparing hot dogs and hamburgers. Finally, you will discover why oil leaks and poor visual management are perceived differently in the workplace compared to a car context, including the use of dashboards, warning lights, signs, and scoreboards. Timestamps: 01:31 Lean Accounting Origins 04:20 Buying in Bulk Trap 06:31 Pull Systems Grocery Lesson 08:05 Utilization Incentives Myth 11:27 Absorption Accounting Reality 12:44 Changeover Barbecue Analogy 17:52 SMED Rethink Changeovers 18:40 Fix Leaks Like Cars 21:38 Visual Management Everywhere 25:16 Bring Lean Home and Work

    29 мин.

  2. 15 ФЕВР.

    Book Review - Accidentally Aligned with Jason Neal

    A shop floor comment stops everyone in their tracks: the work finally matches what the customer actually needs. That is the spark behind Accidentally Aligned, and it opens a bigger issue most leaders dodge: alignment does not come from posters, audits, or a new playbook. It comes from how leaders behave when the process is broken, and the numbers are ugly. Mark and today's guest, Jason Neal, get into the messy middle of transformation: earning trust at the Gemba, protecting dignity when tempers flare, and dealing with the damage caused by "Lean policing." They also tackle a practical trap that shows up everywhere: leaders say they want engagement, then they take away overtime without replacing it with a better system. The result is predictable. So is the fix. If you are trying to keep momentum after the first wave of kaizen, this episode gives you language and moves you can use on Monday morning. Timestamps: 00:06:48 - Accidentally aligned with the customer voice 00:10:24 - Respect for people when the process fails 00:22:38 - Trust as the foundation for Lean sustainment 00:22:51 - When the Lean office becomes an audit function 00:23:37 - Losing credibility by switching to policing behavior 00:25:33 - Stopping disrespect before it becomes normal 00:34:54 - Turning overtime into kaizen time without breaking trust 00:35:12 - Why cutting overtime first backfires

    45 мин.

  3. 1 ФЕВР.

    Are You Set Up to Win? - Find Out Here!

    Most Lean efforts do not stall because people hate improvement. They stall because the system was never built to support it. This episode gives you a fast, practical lens for evaluating whether your organization is built to sustain improvement. You will learn how to recognize common traps that keep Lean efforts stuck, why certain measurement habits create the wrong behavior, and how to distinguish capability building from project theater. By the end, you will have a sharper way to assess your structure, roles, support functions, and operating rhythm, so you can stop guessing and start fixing what is really holding you back. Timestamp highlights 00:02:03 - Calling Lean a "program" is a red flag 00:05:09 - Under-resourced Lean office becomes admin, not a capability builder 00:08:43 - Lean leaders too low in the org cannot move mountains 00:09:55 - Combining Lean with a line role guarantees Lean loses 00:12:03 - Lean office should develop problem solvers, not rack up project points 00:18:36 - Lean audits signal inexperience and tool worship 00:22:54 - One standard problem-solving method beats a mix of A3 8D and random playbooks 00:28:32 - Hino Motors got nine implemented suggestions per person per month by building in time and support 00:32:14 - Value streams in name only when functions still control decisions and measures

    46 мин.

  4. 15 ЯНВ.

    Stop Misusing the 2-Bin Kanban System

    Mark DeLuzio discusses how the 2-Bin Kanban is meant to ensure the operator does not run out of parts.  Find out why it should not be used to structure your primary Kanban system.

    16 мин.

  5. 8 ЯНВ.

    Let's Make 2026 a Year of "Return to the Basics"

    Mark DeLuzio discusses the confusion that exists in the Lean Community, and the Lean Consulting industry and academia are primarily to blame. Returning to Lean Basics and ignoring distractions like Kata, Gemba Walks, Lean certifications, and other consulting “innovations,” which are designed to sell books and consulting services.

    42 мин.

  6. 15.12.2025

    Where Are The Engineers?

    Mark DeLuzio discusses the absence of engineers from the Gemba in both manufacturing and design. He also discusses the sin of engineering, which he calls "Catalogue Engineers."

    20 мин.

  7. 15.11.2025

    Do You Really Understand the Toyota Production System House?

    Mark DeLuzio discusses how the TPS House is not a set of tools, but a way of thinking, and that the tools of Lean support these principles. Starting with the tools before understanding the principles has proven to be the downfall of many companies starting a Lean transformation.

    35 мин.

  8. 01.11.2025

    How Do You Price Your Product?

    Mark DeLuzio discusses the dangers of cost-based pricing as well as the various issues encountered when doing so. He introduces the merits of market-based pricing instead.

    17 мин.
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The Lean 911 Podcast is where you'll have a voice directly from the gemba. Host, Mark DeLuzio, President and CEO of Lean Horizons Consulting and the principal architect of the Danaher Business System, relies on his three decades of lean successes as well as his failures to answer your most challenging questions regarding your lean transformation.

Информация

  • Автор
    Mark DeLuzio
  • Годы выхода
    2023 - 2026
  • Выпуски
    78
  • Ограничения
    Без ненормативной лексики
  • Авторские права
    © 2023-2025 Mark DeLuzio
  • Сайт подкаста
    Lean 911

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